Title: Modern Refrigeration and
1Modern Refrigeration and Air Conditioning
Althouse Turnquist Bracciano
PowerPoint Presentation by Associated Technical
Authors
PublisherThe Goodheart-Willcox Company,
Inc.Tinley Park, Illinois
2Chapter 9
Refrigerants
3Learning Objectives
- Understand the differences between CFCs, HCFCs,
and HFCs. - Correctly identify and classify common
refrigerants by their numbers. - List the necessary properties of refrigerants.
- Read a pressure-temperature curve and identify
the proper refrigerant. - Demonstrate ability to read pressure-enthalpy
diagrams.
4Learning Objectives
- Discuss properties of different refrigerants and
their applications in a system. - Demonstrate handling of refrigerant cylinders and
identify color codes. - Follow approved safety procedures.
- Identify the safety procedures for using
refrigerant cylinders.
5Ozone
9.1
- Contained in a thin layer of Earths upper
atmosphere. - Protects living things on earth from the damaging
effect of the Suns rays.
6Chlorofluorocarbons(CFCs)
9.1.2
- Contained in some refrigerants, such as R-11,
R-12, and R-13. - Scientists have found that CFCs destroy the ozone
layer.
7EPA EnvironmentalProtection Agency
9.1.2
- Identifies the types of refrigerants that can be
produced. - Regulates how refrigerants will be used.
8Four Classificationsfor Refrigerants
9.1
- Chlorofluorocarbons (CFCs).
- Hydrochlorofluorocarbons (HCFCs).
- Hydrofluorocarbons (HFCs).
- Refrigerant blends (azeotropic and zeotropic).
9Identifying Refrigerants
9.1.1
- By number system following the letter R (for
refrigerant). - By color code (on cylinder).
10Identifying Refrigerants
9.1.1
CFC, HFC, and HCFC refrigerants
11Identifying Refrigerants
9.1.1
Zeotropic and azeotropic refrigerants
12CFC (Chlorofluorocarbon) Refrigerants
9.1.2
- First refrigerants to be developed.
- Composed of chlorine, fluorine, and carbon.
- Low in toxicity and noncorrosive.
- Nonflammable and nonexplosive (but should not be
released where flame or electric heating element
is present). - Heat causes CFCs to break down into their
elements, releasing compounds such as phosgene
gas (extremely harmful to the respiratory
system).
13CFC (Chlorofluorocarbon) Refrigerantscontinued
9.1.2
- Common CFCs include R-11, R-12, R-113,
R-114,R-115, R-500, R-502, and R-503. - Azeotropic mixtures classified as CFCs include
R-500, R-502, and R-503. - Believed to be major cause of ozone depletion.
- By international agreement, not manufactured
since 1995. - Laws forbid release of CFCs to the atmosphere.
- Recovery and recycling equipment required when
reclaiming CFCs.
14HCFC (Hydrochlorofluorocarbon)Refrigerants
9.1.3
- Molecules composed of methane or ethane in
combination with a halogen such as R-22 and
R-123. - Causes less ozone depletion due to a smaller
percentage of chlorine. - Reduced potential for global warming.
- EPA requires phase-out of HCFCs by year 2030.
15HFC (Hydrofluorocarbon)Refrigerants
9.1.4
- Contain one or more hydrogen atoms and no
chlorine atoms. - Possess zero potential for ozone depletion.
- Only a slight effect on global warming.
- Includes R-134a and R-23.
- When using R-134a in a retrofit system,
adaptations (hardware changes, lubricant changes,
etc.) must be made.
16Questions
- Which refrigerant is most harmful to the ozone
layer?
CFCs (chlorofluorocarbons)
- Name two chlorofluorocarbon refrigerants.
R-11 and R-12.
- Who regulates refrigerants and how refrigerants
are handled?
The Environmental Protection Agency (EPA).
- How are refrigerants identified?
By number and color code.
17Questions continued
- What happens to CFC refrigerants if they are
exposed to heat?
They break down into their elements, such as
phosgene gas.
- Name two azeotropic mixtures.
R-500 and R-502.
- Name two HCFC refrigerants.
R-22 and R-123.
- Name one HFC refrigerant.
R-134A.
18Refrigerant Blends(Azeotropic-Zeotropic)
9.1.5
- Azeotropic blends do not change or separate in
composition in the refrigeration system. - Zeotropic blends change composition and
saturation when used in a refrigeration system.
19Requirements for Refrigerants
9.2
- Must follow standards set by EPA.
- Nontoxic and nonpoisonous.
- Nonexplosive.
- Noncorrosive.
- Nonflammable.
- Make leaks easy to detect.
- Operate under low pressure (have a low boiling
point).
20Requirements for Refrigerants
9.2
- Stable as a gas.
- Permit refrigerator or compressor parts moving in
the fluid to be easily lubricated. - Have a high liquid volume per pound.
- Have low vapor volume per pound.
- Have as little pressure difference as possible
between evaporating pressure and condensing
pressure. - Meet requirements of all current EPA rules and
regulations.
21Comparison of Refrigerants
9.2
- Based on specific evaporating and condensing
temperatures. - Evaporating temperature of 5F (15C).
- Condensing temperature of 86F (30C).
22Pressure-Temperature Curves
9.3
- Vertical scale is temperature in F.
- Horizontal scale is pressure in psig.
- Temperature shown is always the temperature of
the refrigerant. - Same curve may be used to determine condensing
and evaporating temperatures and pressures.
23Pressure-Temperature Curves
9.3
24Standard Evaporator andCondenser Temperatures
9.3.1
Pressure-enthalpy diagram of an ideal
refrigeration system does not note pressure
drops through evaporator and condenser coils or
inefficiencies of a compressor.
25Grouping and Classificationof Refrigerants
9.4
- Toxicity Ability to be harmful or lethal with
acute or chronic exposure (contact, inhalation,
or ingestion). - American Society of Heating, Refrigerating, and
Air Conditioning Engineers (ASHRAE) classifies
the toxicity of a refrigerant by letter A or B. - Class A refrigerants are not identified as having
a toxicity level. - Class B refrigerants have an identified toxicity
level.
26Grouping and Classificationof Refrigerants
9.4
- Flammability Ability to ignite.
- Number indicates flammability classification.
- Group 1 no flammability identified
- Group 2 low flammability
- Group 3 high flammability
27Grouping and Classificationof Refrigerants
9.4
28Class A Refrigerants
9.5
- May be used in the largest quantities in any
installation. - Includes R-11, R-12, R-22, R-134a, and others.
29R-11 Trichlorofluoromethane
9.5.1
- Synthetic chemical.
- Stable, nonflammable, and nontoxic.
- Considered a low-pressure refrigerant.
- Used in large centrifugal compressor systems.
- Leaks detected using a soap solution, halide
torch, or electronic detector. - Cylinder code color is orange.
- Being replaced by R-123 due to EPA rulings on
CFCs.
30R-12 Dichlorodifluoromethane
9.5.2
- Used in most domestic refrigeration and
automotive air conditioner applications prior to
1997. - Production stopped in U.S. in 1997.
- Limited supply exists for service.
- Colorless, odorless liquid.
- Low latent heat value.
- Boiling point of 21.7F (29.8C).
- Had been used in reciprocating, rotary, and large
centrifugal compressors. - Leak detected by soap solution, halide torch,
colored dye added to system, or electronic leak
detector.
31R-22Chlorodifluoromethane
9.5.3
- HCFC synthetic refrigerant.
- Developed for installations needing low
evaporating temperature. - Used successfully in air conditioning units,
window air conditioners, nonindustrial heat
pumps, and positive displacement chillers. - Used with both reciprocating and centrifugal
compressors.
32R-22Chlorodifluoromethane continued
9.5.3
- Stable, nontoxic, noncorrosive, nonirritating,
nonflammable. - Boiling point of 41F (40.5C).
- Mixes readily with water desiccants should be
used. - Detect leaks with soap solution, halide torch, or
electronic leak detector.
33Questions
- Which type of refrigerant changes its composition
as it is released from its container as a gas?
Zeotropic refrigerants.
- On a pressure-temperature curve, what is the
horizontal scale used for?
psig
- Which classification of refrigerant is most toxic?
Class B refrigerants.
- Which group of refrigerants is most flammable?
Group 3.
34Questions continued
- What is the color code for R-11?
Orange.
- Which refrigerant is replacing R-11?
(HCFC) R-123.
- What is the boiling point of R-12 at atmospheric
pressure?
21.7F (29.8C) at atmospheric pressure.
- Which refrigerant is most commonly used on
air-conditioning equipment?
R-22.
35R-134a Tetrafluoroethane
9.5.4
- HFC refrigerant.
- Used as replacement for R-12.
- Used in centrifugal, reciprocation, rotary screw,
and scroll compressors. - Used as standard refrigerant in automotive air
conditioning. - Nontoxic, noncorrosive, and nonflammable.
36R-134a Tetrafluoroethane continued
9.5.4
- Boiling point of 14.9F (26.1C).
- Not compatible with mineral-based oils. Must use
polyol ester (POE) for most domestic
refrigeration applications and polyalkylene
glycol (PAG) for automotive system use. - Leaks are detected by soap solution or
fluorescent dyes, ultrasonic leak detectors,
halogen-selective detectors, and other electronic
leak detectors.
CAUTION Exposure to concentrations over 75,000
ppm may cause cardiac irregularities.
37Systems Using R-134a as a Replacement for R-12
9.5.4
- Required design changes include 30 increase in
condenser and evaporator sizing, change in
desiccant, smaller hoses, and 30 increase in
control pressure regulators.
38Azeotropic Refrigerants
9.5.5
- Multicomponent working fluid.
- At atmospheric pressure, composition will not
change when it evaporates or condenses. - R-500 and R-502 are azeotropic refrigerants.
39R-500
9.5.5
- Consists of 26.2 R-152a and 73.8 R-12.
- Used in industrial and commercial applications.
- Used only in systems with reciprocating
compressors. - Fairly constant vapor-pressure temperature curve.
- Leaks detected using halide leak detectors,
electronic leak detectors, soap solution, or
colored tracing agents. - Water is soluble with this refrigerant use of
driers recommended. - Boiling point of 28F (33C) at atmospheric
pressure.
40R-502
9.5.5
- Consists of 48.8 R-22 and 51.2 R-115.
- Nonflammable, noncorrosive, practically nontoxic.
- Useful for obtaining medium and low temperatures
0F to 60F (18C to 51C). - Used in frozen food lockers, frozen food display
cases, etc. - Used with reciprocating compressors.
41R-502
9.5.5
- Boiling point 50F (45.5C) at atmospheric
pressure. - Combines many of the best properties of R-12 and
R-22. - Leaks detected with soap solution, halide torch,
or electronic leak detector. - Cylinder code color is orchid.
- R-507A and R-125 are used to replace R-502.
42R-503
9.5.5
- 40.1 R-23 and 59.9 R-13.
- Nonflammable, noncorrosive, and practically
nontoxic. - Boiling temperature is 126F (87.7C).
- Low-temperature refrigerant good for use in the
low section of a cascade system. - Leaks detected using a halide torch, soap
solution, or electronic leak detector. - Applications require extreme dryness or may
result in ice formation.
43R-503
9.5.5
44R-507A
9.5.5
- 50 R-125 and 50 R-143a.
- HFC refrigerant used for low- and medium-
temperature applications as replacement for
R-502. - Colorless, nonflammable, and has a slight odor.
- Boiling point of 52.1F (46.7C).
- Use polyol ester oil as lubricant.
- Color code is teal blue.
- Leaks detected by soap solution, electronic leak
detector, halogen detector, and fluorescent leak
detector.
45Zeotropic Refrigerants
9.5.6
- Working fluids with two or more components.
CAUTION These are patented refrigerants. Never
attempt to make such mixtures.
46R-401A
9.5.6
- Zeotropic blend of 53 HCFC-22, 13 HFC-152a, and
34 HCFC-124. - An alternative for CFC-12.
- Used in most medium-temperature systems, such as
walk-in coolers, food display cases, etc. - Cylinder color code is coral red.
- Can be used with alkyl benzene (AB), polyol ester
(POE), or other oil mixtures, as indicated by
manufacturer. - Leaks detected by halogen detector,
compound-selective detectors, or fluorescent
additive.
47R-406A
9.5.6
- Zeotropic blend of 55 R-22, 4 R-600a
(isobutane), and 41 R-142b. - An HCFC refrigerant, compatible with R-12
systems. - Soluble in mineral and alkyl benzene oils.
- Check with equipment manufacturer for suitability
when using as an alternate refrigerant. - Cylinder color code is light gray-green.
48Group B Refrigerants
9.6
- Toxic!
- Harmful or lethal!
- Acute or chronic exposureby contact, inhalation,
or ingestionmust be avoided!
49Pressure-temperature Curves
9.6
Pressure-temperature curves for some Group B
refrigerants.
50R-123Dichlorotrifluoroethane
9.6.1
- Used as a replacement for R-11.
- Used in centrifugal compressors and in
foam-blowing applications. - Colorless, odorless, and nonflammable liquid.
- Boiling point of 82.2F (27.9C).
- Compatible with mineral oil and alkyl benzene
oil. - Color code is light gray.
51R-717 Ammonia
9.6.2
- Chemical compound of nitrogen and hydrogen.
- Colorless gas under ordinary conditions.
- Boiling temperature is 28F (33C).
- Low boiling point allows for refrigeration at
temperatures well below zero.
CAUTION R-717 is somewhat flammable. With the
proper proportion of air, it will form an
explosive mixture.
52R-717 Ammonia continued
9.6.2
- CAUTION The effect of ammonia on the respiratory
system is violent! - CAUTION Always stand to one side when operating
an ammonia valve. A small valve stem leak may
burn and damage eyes. Instant loss of
consciousness may occur. - CAUTION Wear a tight-fitting respirator.
- To detect R-717, a sulfur candle or sulfur spray
vapor will produce white smokelike fumes. - CAUTION When using or handling ammonia, follow
the safety code provided by the International
Institute of Ammonia Refrigeration.
53R-717 Ammonia continued
9.6.2
- R-717 attacks copper and bronze in the presence
of a small amount of moisture. - Used in large compression machines having
reciprocating compressors and in many
absorption-type systems.
54Questions
- Which HFC refrigerant is the replacement for R-12?
R-134A
- What type of oil must be used with R-134A?
Polyol ester (POE).
- Which azeotropic refrigerants are used for
low-temperature systems?
R-502 and R-503.
- Which azeotropic HFC refrigerant is used as a
replacement for R-502?
R-507A.
55Questions continued
- Which type of refrigerant is R-401A, an
azeotropic or a zeotropic blend?
Zeotropic blend.
R-12.
- Which refrigerant does R-401A replace?
- Which highly toxic refrigerant is a replacement
for R-11?
R-123.
- What is the chemical composition of ammonia?
Nitrogen and hydrogen (NH3).
- Which metals cannot be used with R-717?
Copper, brass, or bronze.
56Combustible Refrigerants
9.7
CAUTION Some refrigerants may form a flammable
material when mixed with air!
- The ASHRAE Safety Classifications are 2 (low
flammability) or 3 (high flammability). - Refrigerants in these categories include R-406A
and R-717. - Includes methylene chloride R-30, methyl
chlorideR-40, methane R-50, ethane R-170,
propane R-290, zeotropic mixtures (R-22, R-600a,
and R142b),R-406A, butane R-600, and ammonia
R-717.
57Expendable Refrigerants
9.8
- Expendable refrigerants cool a substance or
evaporator and are then released to the
atmosphere. - Systems using expendable refrigerants are
referred to as chemical refrigeration or
open-cycle refrigeration systems. - Refrigerants of this type have a low boiling
temperature. - Include liquid nitrogen R-728, liquid helium
R-704, and carbon dioxide R-744.
58Water as a Refrigerant
9.9
- Water is never used in the compression-cycle
refrigerating mechanism. - Water is used in steam jet refrigeration for air
conditioning systems.
59Cryogenic Fluids
9.11
- Range in temperature from 250F (157C) to
absolute zero (459.69F or 273C). This is
referred to as the cryogenic range. - Common cryogenic fluids are hydrogen R-702,
helium R-704, neon R-720, nitrogen R-728, air
R-729, oxygen R-732, and argon R-740. - Containers for cryogenic fluids must be heavily
insulated the temperature of the fluids inside
is very low.
60Cryogenic Fluids continued
9.11
- CAUTION Do not use these fluids in any container
or mechanism that was not designed for such use. - CAUTION Cryogenic fluids must never touch the
skin since this will result in immediate freezing
of the flesh. When handling cryogenic fluids, the
entire body must be protected.
61Refrigerant Cylinders
9.12
- Regulations for cylinders are prescribed by the
Department of Transportation (DOT). There are
three types of cylinders - Storage cylinders.
- Returnable service cylinders.
- Disposable cylinders.
62Storage Cylinders
9.12.1
- Must be dated and stamped with a DOT stamp.
- May not be used beyond six years from date shown.
- Must be returned to manufacturer every six months
for checking. - Cylinder valves are of the one-way type.
- Keep packing nut tight unless the valve is being
used. - Seal opening with a plug or cap when not in use.
CAUTION Use a hoist to lift and move cylinders
weighing over 35 pounds.
63Service Cylinders
9.12.2
- Small, refillable cylinders (4 lbs. to 25 lbs.)
can be carried by the technician. - Cylinder valve fitted with 1/4" male flare.
- Liquid refrigerant expands with an increase in
temperature. - Weigh service cylinders before and after filling.
- Cylinders completely filled with cold or cool
refrigerant will burst if warmed up.
CAUTION Never completely fill a cylinder with
liquid refrigerant! Allow space for
expansion. A safe limit is 80 full.
64Returnable Service Cylinders
9.12.2
- Refrigeration supply houses provide service
cylinders on an exchange basis. - A liquid-vapor valve is available. It allows
charging as a vapor or liquid without inverting
the cylinder.
65Returnable Service Cylinders
9.12.2
66Returnable Service Cylinders
9.12.2
67Disposable Cylinders
9.12.3
- Contain small quantities of refrigerant, from a
few ounces to 50 lbs. - Eliminates the need for refilling.
- Most are fitted with relief valves located in the
valve body.
CAUTION Never recharge a disposable cylinder. Do
not use a disposable cylinder to store
refrigerant removed from a system.
68Disposable Cylinders
9.12.3
69Questions
- Name two combustible refrigerants.
R-290 (propane) and R-600 (butane).
- Which group of refrigerants is highly flammable?
Group 3.
- Where are expendable refrigerants used?
In open-cycle refrigeration systems.
- Name three expendable refrigerants.
Liquid nitrogen, liquid helium, and carbon
dioxide.
70Questions continued
- What is the temperature range for cryogenic
refrigerants?
The temperature range is from 250F (157C) to
absolute zero 459.69F (273C).
- Which organization approves storage cylinders?
Department of Transportation (DOT).
- Which type of cylinder must never be refilled?
A disposable cylinder.
71Pressure-Temperature Tables
9.13
- Display the pressure-temperature relationship of
a refrigerant under saturated conditions. - Latent heat, specific heat, and density of liquid
are shown. - Find the temperature being investigated in the
vertical left-hand column. Move across the
columns horizontally to find the pressure.
72Head Pressures (High Side)
9.14
- Pressures vary with refrigerants.
- Air-cooled condenser high-side temperature should
be between 30F (17C) and 35F (19C) higher
than the ambient temperature. - Water-cooled condenser high-side temperature
should be 15F (8C) to 20F (11C) above the
exhaust temperature of the water. - Condensing temperature will rise until the heat
loss from the condenser equals the heat input to
the condenser.
73Causes for Above-Normal Head Pressures
9.14
- Air trapped in the condenser.
- Overcharge of refrigerant in systems with a
low-side float, expansion valve, or thermostatic
expansion valve. - Blockage or poor water flow in condenser.
- Restriction in system, such as clogged capillary
tube or stuck refrigerant control. - Above normal low-side pressure.
74Refrigerator Temperatures
9.15
- Cabinet temperatures are fairly standard.
- Must have correct-size evaporator for the
temperature desired. - Refrigerant will be 10F (6C) colder than the
evaporator temperature when unit is running. - Refrigerant and evaporator will become the same
temperature during the off cycle.
75Refrigerant Applications
9.16
- Manufacturer determines type of refrigerant used
in a unit. - Considerations in selection of refrigerant
include - System capacity.
- Volume of the vapor pumped.
- Latent heat of the refrigerant.
- Operating temperatures required.
- Size of the equipment.
76Changing/Identifying Refrigerants
9.17
- Retrofitting Changing the type of refrigerant in
a unit. - Check manufacturers tags on the equipment.
- When retrofitting, contact manufacturer to see if
components must be modified. - Note Always use the proper recovery/recycle
equipment when changing refrigerants.
CAUTION Do not sniff refrigerant this can be
deadly!
77Amount of RefrigerantRequired in a System
9.18
- Varies with type of system.
- Low-side float, automatic expansion valve, and
thermostatic expansion valve systems are not
sensitive to amount of refrigerant charge. - High-side float systems and capillary tube
systems are very sensitive to amount of
refrigerant charge. - Sight glass in liquid line allows for
determination of sufficient amount of
refrigerant. - Bubbles in sight glass mean charge is low.
78Refrigeration Oil
9.19
- Circulates through system with refrigerant.
- Provides lubrication and cools compressors
moving parts. - Must withstand extreme temperatures.
- Oil removed from a system should be clear.
- If oil removed is discolored, new driers and
filters should be placed in system. - Use only oil recommended by manufacturer.
- Keep oil containers tightly sealed.
79Properties of aGood Refrigerant Oil
9.19
- Low wax content.
- Good thermal stability.
- Good chemical stability.
- Low pour point.
- Low viscosity.
80Moisture in Refrigerant
9.20
- May freeze at the refrigerant control.
- May cause refrigerant to break down and form
harmful acids. - A moisture indicator placed in the liquid line
may detect moisture in a system. - If moisture is noted, a new filter-drier should
be installed. - It may be necessary to replace the drier several
times to remove sufficient moisture. - When servicing, avoid exposing cold internal
parts to air.
81Safety
9.21
- Wear goggles and gloves at all times, especially
when charging or discharging refrigerant. - Liquid refrigerant may freeze the skin. Wash with
water, treat for frostbite, and refer to a
doctor. - Refrigerants R-717 and R-764 are very irritating
to the eyes and lungs. Avoid exposure to them. - Refrigerant oil in hermetic compressors may be
acidic. Never allow it to touch the skin. - If a leak is suspected, thoroughly ventilate the
room prior to working on the unit.
82Safety continued
9.21
- Many refrigerants are heavier than air and will
replace the air in a room. This is VERY
dangerous! Instruments are available to warn if
oxygen content is below a safe level. - Sniffing refrigerant can cause death.
- Always use proper recovery/recycle equipment when
changing refrigerants. - Always check for recommended operating pressures
for each refrigerant. - To avoid mixing refrigerants, check the R-number
prior to charging.
83Safety continued
9.21
- There must be no lighted flames near a system
suspected of a fluorocarbon refrigerant leak. - Always charge refrigerant vapor into the low side
of the system. - Moisture should not be allowed to enter a
refrigerating system. - Containers of oil must be kept tightly sealed.
- Never fill a service cylinder more than 80 full.
- Always check the DOT cylinder stamp to be sure
the cylinder is safe. - Store refrigerant cylinders in a cool, dry place.
84Questions
- On an air-cooled condenser, how high is the
operating condenser temperature when compared to
ambient temperature?
30ºF (17C) to 35ºF (19C) degrees higher.
- On a water-cooled condenser, how high is the
operating condenser temperature when compared to
the leaving water?
15ºF (8C) to 20ºF (11C) degrees higher.
- Name three possible causes for high head pressure.
Overcharged system, blocked airflow over the
condenser, air trapped in the condenser.
85Questions continued
- Bubbles in a sight glass are usually an
indication of
A low refrigerant charge.
- Does the oil in the compressor circulate with the
refrigerant during the on cycle?
Yes.
- Which of the following is a good property of
refrigerant oil, low viscosity or high viscosity?
Low viscosity.
- Name two problems that moisture can cause in a
refrigeration system.
The formation of acids and freeze up at the
refrigerant control.
86Glossary
- flammability
- Tendency to ignite.
- ozone
- A form of oxygen having three atoms to the
molecule. The ozone layer is the outermost layer
of the earths atmosphere. It absorbs ultraviolet
light from the sun and shields the lower layers
and the earth from harmful rays. - retrofit system
- Updating of an existing system to new standards.
- retrofitting Changing the type of refrigerant in
a system. - toxicity
- Measure of the amount of poison in a substance
or the amount of harm it can cause.